Type III PCMCIA card with integrated receptacles for receiving standard communications plugs

ABSTRACT

A Type III PCMCIA communications card for insertion in a slot in a host computer comprises a housing including a top wall and longitudinal, parallel side walls depending from the top wall, the longitudinal side walls and top wall defining an internal cavity enclosed by a bottom cover panel. The housing further has a forward end, a rear margin and a rear end surface, the rear margin of the housing defining at least one substantially longitudinally oriented receptacle extending forwardly from the rear end surface and sized and configured to receive a standard RJ-type modular plug. A substrate, mounted within the cavity of the housing, supports electronic components for carrying out the communications function. The substrate has a rear margin carrying a contact block including a plurality of contact wires, each contact wire having a first portion connected to components on the substrate, and a second portion extending into the at least one receptacle, the second portion of the contact wire being shaped and positioned for engagement with a corresponding contact on the connector plug. A connector provided at the forward end of the housing is adapted to be received by a corresponding connector within the slot of the host computer. The card has an overall height not exceeding approximately 10.5 mm, the communications card being directly connectable to a digital information system such as a LAN or a telephone line system utilizing standard RJ-type connectors.

CROSS REFERENCE TO RELATED APPLICATION

This is a continuation of application Ser. No. 09/048,143 filed Mar. 25,1998, (now U.S. Pat. No. 6,116,962) which is a continuation-in-part ofapplication Ser. No. 08/971,501 filed Nov. 17, 1997 (now U.S. Pat. No.5,984,731 issued Nov. 16, 1999), both of which applications are herebyincorporated by reference in their entirety.

This application is a continuation of application Ser. No. 09/048,143filed Mar. 25, 1998, which is a continuation-in-part of U.S. applicationSer. No. 08/971,501 filed Nov. 17, 1997, now U.S. Pat. No. 5,984,731.

FIELD OF THE INVENTION

This invention relates generally to removable input/output (I/O) devicesof the type used with host systems such as desktop and portable personalcomputers, peripherals, and the like, for directly connecting the hostsystem to an information transfer system using standard modularcommunications plugs.

BACKGROUND OF THE INVENTION

As is well known, many of today's laptop, notebook, desktop and othercomputers, as well as computer peripherals and other electronicproducts, are designed to receive removable devices such as cardsconforming to standards established by the Personal Computer Memory CardInternational Association (PCMCIA). These standards define theelectrical and physical specifications of the card including theinterfaces between the card and the port or slot into which the card isinserted. The specifications include a 16-bit PC Card interface and a32-bit CardBus interface. The PCMCIA standards also specify three cardform factors, called Type I, Type II and Type III. All three card typesmeasure the same length (85.6 mm) and the same width (54.0 mm), anddiffer only in overall thickness. Thus, the Type I card has a thicknessof 3.3 mm; the Type II card, 5.0 mm; and the Type III card, 10.5 mm.PCMCIA cards may be used for various purposes. For example, Type I cardsare typically used for memory devices; Type II cards are typically usedfor I/O devices, as will be described below; and Type III cards aretypically used to house rotating mass storage devices (disk drives).Presently, Type II cards are used principally as communication links,for example, for connecting the user of a host system such as a portablecomputer to an Ethernet LAN, as a data/fax modem for connecting the userto a subscriber telephone line system, or as a combined LAN and modemcard. In one popular arrangement, an adapter cable is used to couple therelatively thin Type II card to the much larger, standard RJ-11 or RJ-45receptacle of a telephone line or Ethernet network. A drawback of thisarrangement is that one or more bulky adapter cables must be carried (inaddition to the computer) by the computer user in order to connect thecomputer to a LAN or telephone line system thereby defeating at least tosome extent the advantages afforded by portable computers; also, theseadapter cables are often lost. Another disadvantage of adapter cables isthat the connection between the thin card and the cable is inherentlyfragile mechanically and subject to losses of electrical contact with aconsequent loss of data transfer.

One solution to the problem of incompatibility between the PCMCIA TypeII standard communications card and the RJ-type connector is to add tothe rear end of the Type II card an enlarged housing enclosing areceptacle sized and configured to receive an RJ-type connector plug.The incorporation of such an RJ receptacle housing allows the 5 mm TypeII communications card to interface directly with a LAN or telephonesystem using an existing LAN or telephone cable with an RJ-11 or RJ-45modular plug at each end. However, although this approach eliminates theneed for a separate adapter cable assembly, the housing on the end ofthe card for receiving the RJ-type connector projects from the hostsystem enclosure often requiring the removal of the card whentransporting a portable computer in an attache case or the like.

Another approach to the elimination of the need for external adaptercables is a communications card that allows an RJ-type modular plug tobe inserted directly into an aperture formed in a retractable accessportion of a Type II communications card. Such an approach is disclosed,for example, in U.S. Pat. No. 5,183,404 issued Feb. 2, 1993. Yet anotherapproach to eliminating the need for adapter cables is disclosed inInternational Application No. PCT/US94/13106, published May 18, 1995under the Patent Cooperation Treaty (PCT) as Publication No. WO 95/13633(corresponding to U.S. Pat. No. 5,773,332). FIG. 21 of this PCTpublication shows a Type III card incorporating in the rear thereof apair of RJ-xx series receptacles (specifically RJ-11 and RJ-45) fordirectly connecting the card to a LAN network and/or telephone line.

An overall object of the present invention is to provide an improvementof the device disclosed in the aforementioned PCT publication.

SUMMARY OF THE INVENTION

In accordance with one specific, exemplary embodiment of the invention,there is provided a device adapted to be received by a port in a hostsystem for connecting the host system to a digital information transfersystem. The device comprises a housing having longitudinal sides, atransverse front end and a rear portion, at least the rear portion ofthe housing conforming substantially to the PCMCIA Type III thicknessstandard. A substrate enclosed within the housing carries circuitelements and a connector at the front end of the housing is connected tocircuit elements on the substrate. The connector is adapted to bereceived by a corresponding connector within the slot of the hostsystem. The rear portion of the housing defines at least one forwardlyextending receptacle, the at least one receptacle including contactwires coupled to circuit elements on the substrate. The at least onereceptacle is sized and configured to receive a standard RJ-type modularplug, the modular plug including contacts adapted to engage the contactwires in the at least one receptacle when the plug is inserted in thereceptacle so that the device is adapted to be directly connectable tothe digital information transfer system utilizing the standard RJ-typeplug. The substrate includes a rear margin carrying a contact blockhaving a plurality of contact wires. Each contact wire has a firstterminal portion, or solder tail, connected to circuit elements on thesubstrate, and a second terminal portion extending into the at least onereceptacle, the second terminal portion of the contact wire being shapedand positioned for engagement with a corresponding contact on theRJ-type modular plug.

In accordance with another aspect of the invention, the contact blockcomprises a base and a transversely extending, vertical wall mounted onthe base. The wall has a front face, a rear face and a bottom face, andfurther includes at least one contact section adapted to make electricalconnection with said at least one modular plug. The at least one contactsection of the wall includes surfaces for retaining the contact wiresagainst lateral displacement and further includes a recess in the bottomface. A plurality of shaped contact wires are carried by the contactblock, each contact wire including portions engaging the contact wireretaining surfaces, each contact wire further including a first terminalportion or solder tail extending into the recess for connection to thesubstrate and a second terminal portion extending from the rear face ofthe wall, the second terminal portion being adapted to be engaged by acorresponding contact on the modular plug.

In accordance with yet another aspect of the invention, the firstterminal portion or solder tail of each contact wire extends rearwardlywithin the associated recess and a portion of the rear face of thevertical wall of the contact block is shaped to facilitate access to thesolder tail of each contact wire. Preferably, the shaped portion of therear face of the vertical wall comprises a beveled surface.

The contact block is designed to minimize its encroachment on theadjacent substrate. Thus, the rearwardly extending solder tail of eachcontact wire is connected to the traces on the rear margin of thesubstrate as close as practicable to the rear edge thereof. Afterfabrication of the subassembly comprising the substrate and contactblock, the recesses and beveled surfaces defined by the contact blockwall facilitate inspection of the integrity of the solder jointsconnecting the contact wire solder tails to the substrate and providesufficient space to permit resoldering if necessary.

In accordance with another aspect of the present invention, there isprovided an improved enclosure for an I/O device adapted to be receivedby a port in a host system. The improved enclosure comprises a housingincluding a top wall and longitudinal, parallel side walls dependingfrom the top wall, the longitudinal side walls and top wall defining aninternal cavity for receiving a substrate carrying electroniccomponents. The housing further has a forward end, a rear portion and arear end surface, the rear portion defining at least one receptacleextending forwardly from the rear end surface and sized and configuredto closely receive a standard RJ-type modular plug. At least the rearportion of the housing conforms substantially to the PCMCIA Type IIIthickness standard. A bottom cover panel encloses the cavity, the bottomcover panel including parallel, upwardly extending side flangesconfigured to nest within the side walls of the housing. In accordancewith another feature of the improved I/O device enclosure, the sidewalls of the housing and the upwardly extending side flanges of thebottom cover panel are adapted to receive and retain longitudinal sidemargins of the substrate. The housing and bottom cover panel therebydefine an enclosure maximizing the usable substrate surface area. Stillfurther,the housing may comprise a one-piece, unitary molded plasticstructure. Alternatively, to facilitate fabrication of the enclosure,the rear portion of the housing may constitute a receptacle bodydefining the at least one receptacle, the receptacle body and theremainder of the housing comprising separate, molded plastic structuresbonded by sonic welding, for example, along mating joinder surfaces.

BRIEF DESCRIPTION OF THE DRAWINGS

Further objects, features and advantages of the invention will becomeevident from the detailed description below when read in conjunctionwith the accompanying drawings in which:

FIG. 1 is a perspective view of a device in accordance with the presentinvention for connecting a host system and an information transfersystem, at least the rear portion of the device substantially conformingto the Type III PCMCIA thickness standard and incorporating receptaclesfor receiving standard connector plugs of the RJ and “slim D-sub” types;

FIG. 2 is a top plan view of the device shown in FIG. 1;

FIG. 3 is a side elevation view of the device shown in FIG. 1;

FIG. 4 is a bottom plan view of the device shown in FIG. 1;

FIG. 5 is a front elevation view of the device shown in FIG. 1;

FIG. 6 is a rear elevation view of the device shown in FIG. 1;

FIG. 7 is an exploded, perspective view of the device of FIG. 1 showingthe major components thereof;

FIG. 8 is a transverse, cross section view of the device of the presentinvention, as seen along the line 8—8 in FIG. 3;

FIG. 9 is a side elevation view, in cross section, of the rear portionof the device of FIG. 1, as seen along the line 9—9 in FIG. 6, showingdetails of one of the RJ-type connector receptacles and an associatedcontact block;

FIG. 10 is a side elevation view, in cross section, similar to FIG. 9,showing an RJ-type modular plug inserted in its associated receptacle;

FIG. 11 is a perspective view of a subassembly of the device of FIG. 1,the subassembly including an electronic component substrate and acontact block and slim D-sub receptacle mounted along the rear margin ofthe substrate;

FIG. 12 is a perspective view of a subassembly of the device of FIG. 1,the illustrated subassembly comprising a receptacle body and matingcontact block;

FIG. 13 is a perspective view of a specific embodiment of a contactblock that may be utilized in the present invention;

FIG. 14 is a perspective view of a specific embodiment of a receptaclebody that may be utilized in the present invention;

FIG. 15 is a another perspective view of the receptacle body shown inFIG. 14;

FIGS. 16-19 are perspective views of receptacle bodies in accordancewith alternative embodiments of the invention;

FIG. 20 is a rear perspective view of an alternative embodiment of acontact block that may be employed in the present invention;

FIGS. 21 and 22 are front perspective views of the alternative contactblock of FIG. 20;

FIG. 23 is a bottom plan view of a housing in accordance with theinvention incorporating the contact block of FIGS. 20-22, the housingbeing shown without the bottom cover, substrate or front connector; and

FIG. 24 is a side elevation view, in cross section, of the rear portionof the housing of FIG. 23 as seen along the line 24—24 in FIG. 23, withthe bottom cover and substrate in place.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It should be noted that terms such as “top”, “bottom”, “upper”, “lower”,“vertical”, “horizontal”, and the like, are used herein only tofacilitate the description of the structure of the card illustrated; itwill be evident that the card may be used in any orientation.

Although it will be evident to those skilled in the art that theremovable I/O device of the present invention has broad utility, beingusable with a wide variety of standard connector systems including bothcommunication connector systems (for example, telephone and LAN) andnon-communication connector systems (for example, video, coax, BNC, andso forth), the description of the invention will focus primarily onremovable PCMCIA communication cards connectable to RJ-type standardmodular connectors as a specific, exemplary context for the invention.By “RJ-type” standard modular connectors is meant RJ-11, RJ-45, and likemodular connectors used, for example, for telephone line and LANoperations.

Referring to FIGS. 1-6, there is shown a preferred embodiment of thepresent invention comprising a PCMCIA card 10, conforming to the PCMCIAinterface standard, and combining the functions of an Ethernet LANadapter and a telephone line modem. The card 10 also supports variouscellular wireless communication standards as will be described below.There is also shown (in FIG. 1) a host system 12, such as a desktop orportable computer, or computer peripheral, having a PCMCIA card port 14for receiving the card 10.

The card 10 includes opposed, parallel, forward and rear ends 16 and 18,respectively, and parallel, longitudinal sides 20 and 22. The card 10further has a top exterior surface 24 and a bottom exterior surface 26.The top surface 24 has a planar rear surface portion 28 parallel withthe bottom surface 26 and a sloping or curved forward portion 30. Itwill be evident that the forward portion 30 of the top exterior surface24 need not be sloped or curved; the entire top surface 24 of the cardmay simply comprise a flat surface extending forwardly from and coplanarwith the planar rear surface portion 28.

In accordance with the physical standards established for all PCMCIAcards, the card 10 has a length of about 85.6 mm and a width of about54.0 mm. The parallel top and bottom exterior surfaces 28 and 26 definean overall card thickness of about 10.5 mm in accordance with the TypeIII PCMCIA card form factor. In the specific embodiment underconsideration, the forward end 16 of the card may have a thickness ofabout 5 mm matching that of a Type II card. (As is known, a Type IIIcard port (such as the port 14) can accommodate two stacked Type IIcards.)

Disposed along the forward end 16 of the card 10 is a multicontactconnector 34 designed to be removably coupled to a correspondingmultipin connector (not shown) within the slot 14 in the host system 12.The connector 34 is made of molded plastic and, in accordance with thePCMCIA standard, includes sixty eight (68) contacts arranged in two rowsof thirty four (34) contacts each. The connector contact and pinassignments are established by the PCMCIA interface standard. Theconnector 34 further includes a rear transverse face 40 from whichcontact leads 42 project (FIG. 7).

Referring now also to FIGS. 7-15, the card 10 is basically defined by amolded plastic housing 50 including longitudinal side walls 52 and 54depending from a top wall 56. The walls 52, 54 and 56 define a centralcavity 58 enclosed by a bottom sheet metal cover panel 60 having a rearmargin 62 configured to define a pair of tabs 64, and upwardly extendingside flanges 66 and 68 nested within the side walls 52 and 54 of theplastic housing 50 (FIG. 8).

In accordance with a preferred form of the invention, the housing 50includes a front, molded plastic main housing part 70 and a separatelymolded, rear plastic receptacle body 72. The main housing part 70 andreceptacle body 72 are permanently bonded, for example, by an adhesiveor by sonic welding, along matching, arcuate joinder surfaces 74 and 76.The separate molding of the main housing part 70 and the receptacle body72 facilitates manufacture, but it will be evident that alternatively,the housing part 70 and receptacle body 72 may be comolded, that is,molded as one piece to form a unitary housing 50.

The receptacle body 72, in the embodiment illustrated, includes four (4)sections 80, 82, 84 and 86 defined by longitudinally extending verticalwalls 88, 90, 92, 94 and 96 and top wall 98. Sections 82, 84 and 86comprise receptacles sized, configured and oriented to closely receivestandard RJ-type modular connector plugs in a generally longitudinalinsertion direction. Thus, by way of example and not limitation, eachreceptacle 82 and 84 is designed to receive a standard RJ-11 modularplug for direct connection to a telephone line for data/fax modemtransmissions while the receptacle 86 is designed to receive a standardRJ-45 modular plug for direct connection to a LAN system. Although theRJ-45 plug is wider than the RJ-11 plug, the heights of these standardplugs are identical. The receptacle 84 can directly receive the RJ-11plug on the end of an existing telephone line cable while the receptacle82 can function as a pass-through and thus can be used, optionally, forconnection to a modular telephone by means of an adapter telephone linehaving an RJ-11 modular plug on each end.

By way of example, a conventional RJ-11 modular plug 100 for insertionin the receptacle 82 is shown in FIGS. 1 and 10. As is well known, themodular plug 100 includes a main rectangular body 102 having paralleltop and bottom faces 104 and 106 and contact pins 108 connected to amulticonductor telephone cable 110 whose other end (not shown) has anidentical RJ-11 modular plug. The standard plug 100 also includes aspring retention clip 112 having bilateral, transverse abutment surfaces114.

The sizes and configurations of the receptacles 82, 84 and 86 areidentical except that, as already noted, the width of the receptacle 86,which receives an RJ-45 modular plug, is greater than that of thereceptacles 82 and 84 which each receive an RJ-11 plug. Accordingly,taking the receptacle 82 as typical of the three RJ receptacles of thepreferred embodiment, the receptacle 82, which is defined by side walls90 and 92 and top wall 98, has a modular plug access opening 120 alongthe rear end surface 18 of the card and an open or cutout bottom 122having a T-shaped configuration. The side walls 90 and 92, at theirlower ends, include inwardly directed flanges 124 and 126 definingledges 128 and 130, respectively. The ledges 128 and 130, in conjunctionwith the top wall 98, define a channel 132 for receiving the main body102 of the modular plug 100. The top wall 98 has an interior horizontalsurface 134 including a plurality (six, in the case of receptacle 82) ofuniformly spaced-apart, longitudinally extending grooves 136 forreceiving the end portions of contact wires, as will be described below.

The representative receptacle 82 further includes an integrally moldedpair of lugs 138 and 140 projecting inwardly from the flanges 124 and126, respectively. As seen in FIGS. 14 and 15, for example, the inwardlydirected flanges 124 and 126, together with the lugs 138 and 140, definethe T-shaped opening or cutout 122 in the bottom of the receptacle 82.The lugs 138 and 140 are positioned for engagement by the abutmentsurfaces 114 on the retention clip 112 of the associated RJ modular plug100. Thus, in a well known fashion, the abutment surfaces 114 on theretention clip 112 interact with the lugs 138 and 140 to lock themodular plug 100 into the receptacle 82 when the plug 100 is fullyinserted, with the retention clip 112 projecting downwardly through thebottom opening 122 as best seen in FIG. 10. To minimize the depth of thereceptacle 82, the lugs 138 and 140 are positioned at the rear extremityof the receptacle immediately adjacent the plug access opening 120.

With reference to FIG. 15, the walls 92 and 94 include lower surfaces142 and 144, respectively, defining recesses 146 and 148 for receivingthe tabs 64 along the rear margin 62 of the bottom cover panel 60.

Disposed within the cavity 58 defined by the housing 50 is a substratein the form of a printed circuit board assembly (PCBA) 160 having topand bottom surfaces 162 and 164 carrying integrated circuits and otherelectronic components, such as the components 166 shown schematically inFIGS. 7, 8 and 11. The PCBA 160 has longitudinal side margins 168 and170 captured between the side walls 52 and 54 on the housing 50 and theflanges 62 and 64 of the bottom cover panel 60 (FIG. 8). As seen in FIG.7, the card connector 34 is mounted along a forward margin 172 of thePCBA 160, the leads 42 from the connector 34 being soldered to aterminal section along the forward margin 172.

With reference to FIGS. 7 and 9-13, the PCBA 160 has a rear margin 174along which is mounted a connector contact block 180 having threesections 182, 184 and 186 corresponding to the RJ connector receptacles82, 84 and 86, respectively. The section 182 of the contact block 180 isrepresentative of the RJ connector contact block sections. The contactblock 180 may be supplied in tape and reel form and, usingpick-and-place and surface mount technologies, connected to traces onthe top surface 162 of the PCBA 160 along the rear margin 174 thereof(FIG. 11).

The contact block 180, preferably molded from plastic as a single piece,comprises a rearwardly projecting base 188, a transverse vertical wall190, and posts 192 joining the base 188 and wall 190. The base 188 has alower planar, recessed surface 194 to which the rear margin 62 of thebottom cover panel 60 is bonded. The vertical wall 190 of the contactblock 180 has a lower extremity comprising a planar, horizontal PCBAabutment surface or bottom face 196 engaged by and bonded to the uppersurface of the rear margin 174 of the PCBA 160. Locating pins 198projecting from the abutment surface 196 are received by correspondingholes 200 in the PCBA 160 and serve to precisely position the contactblock 180 relative to the PCBA. The portion of the wall 190corresponding to representative section 182 of the contact block 180 hasan upper part including a plurality of parallel, longitudinallyoriented, equally spaced apart, contact wire guide slots 202. Generally,the portions of the wall 190 of the contact block sections 182 and 186associated with the RJ-11 receptacles are provided with six (6) slots toaccommodate up to as many contact wires, while the portion of the wallassociated with the RJ-45 receptacle has eight (8) slots. Below theslots 202 is a recess 204 extending upwardly from the PCBA abutmentsurface 196. Each slot 202 communicates with the associated recess 204via a vertical contact wire retention aperture 206.

As best seen in FIG. 15, the receptacle body vertical walls 90, 92 and94 have front edges 210, 212 and 214 configured to be closely receivedby notches 216, 218 and 220 in the wall 190 and posts 192. Further, thebase 188 of the contact block 180 has a pair of upstanding projections222 adapted to be received by apertures 224 in the receptacle body 72.

When the receptacle body 72 and the contact block 180 are in theirfinal, assembled configuration (FIG. 12), the slots 202 in the contactblock wall 190 and the grooves 136 in the interior surface 134 of thetop wall 98 of the receptacle body 72 are in longitudinal alignment.Thus, generally speaking, there will be a corresponding groove 136 foreach slot 202. Each contact block section 182, 184 and 186 carries aplurality of contact wires. For example, the representative section 182carries contact wires 230 each comprising a first terminal portion inthe form of a horizontal solder tail 232 soldered to a trace along theupper surface of the rear margin 174 of the PCBA 160; a vertical run 234extending through one of the contact wire retention apertures 206 into acorresponding slot 202; and a horizontal portion 236 extending forwardlyfrom the slot 202. A second terminal portion 238 of the contact wire 230is formed by bending the wire rearwardly as best seen in FIGS. 9, 10 and13 from the horizontal portion 236 to form an angled spring biasedcontact for engagement by a corresponding contact pin 108 on theassociated RJ modular plug 100. Each slot 202 is defined by laterallyspaced apart, longitudinally extending, vertical surfaces 203 whichrestrain the associated contact wire against lateral movement. A rearextremity 240 of each contact wire 230 is captured by the correspondinggroove 136 in the top wall 98 of the receptacle body 72 to stabilize itsposition and prevent damage to it upon insertion of the modular plug100.

As best seen in FIGS. 9, 10 and 12, the contact block 180 is designed tominimize its encroachment on the adjacent printed circuit board assembly160. Thus, the forwardly extending solder tail 232 of each contact wire230 is contained substantially within the longitudinal confines of therecess 204 and is connected to the traces on the rear margin 174 of thePCBA 160 as close as practicable to the rear edge of the PCBA. Afterfabrication of the subassembly shown in FIG. 11, the recesses 204facilitate inspection of the integrity of the solder joints connectingthe contact wire tails 232 to the PCBA and provide sufficient space topermit resoldering if necessary. Compact design is also afforded bybending the wire 230 forwardly to form the horizontal wire portion 236and then rearwardly at an appropriate angle to provide a sufficientlylong and therefore compliant rearwardly extending terminal portion 238.It will be seen that the portions of the contact wire 230 forward of thecontact block 180 do not interfere with the PCBA or any of the devicescarried thereby.

The rear end 18 of the card 10 also includes an opening 250 configuredto receive a slim D-sub plug for coupling the host system 12 to acellular telephone permitting wireless communications. A mating slimD-sub connector body 252, positioned to receive the slim D-sub plug, ismounted on the rear margin 174 of the PCBA adjacent the contact block inalignment with the opening 250.

With reference to FIGS. 20-24 there is shown an alternative embodimentof a contact block identified by the reference numeral 300, having threeconnector sections 302, 304 and 306 corresponding to as many RJconnector receptacles as already described in connection with theembodiment of FIG. 13. The connector section 304 (through which thecross section of FIG. 24 is taken) is representative of the RJ connectorcontact block sections. As before, the contact block 300 may be suppliedin tape and reel form and, using pick-and-place and surface mounttechnologies, connected to traces on the upper surface 308 of asubstrate in the form of a PCBA 310 along the rear margin 311 thereof(FIG. 24).

The contact block 300 includes a main body 312 preferably molded fromplastic as a single piece, and comprises a rearwardly projectinghorizontal base 314, a transverse vertical wall 316 and posts 318joining the base 314 and wall 316. The vertical wall 316 of the contactblock has a lower extremity comprising a planar, horizontal PCBAabutment surface or bottom face 320 adapted to engage the upper surface308 of the PCBA 310 along the rear margin 311 thereof. Associated withthe connector sections 302, 304 and 306 are recesses 322, 324 and 326,respectively, formed in the wall 316 and extending upwardly from thebottom face 320 thereof. Metal locating pins 328, provided at theopposite ends of the contact block 300, project from the abutmentsurface 320. The pins 328 are received by corresponding holes in thePCBA 310 so as to precisely position the contact block 300 relative tothe PCBA 310. The locating pins 328 may be soldered to the PCBA 310 tofirmly secure the contact block 300 to the PCBA. The opposite ends ofthe contact block wall 316 includes mounting protuberances 330 and thebase 314 includes a pair of projections 331.

The wall 316 includes vertical, transversely extending, parallel frontface and rear faces 332 and 334, respectively. The rear face 334 of thewall 316 includes beveled surfaces 336, 338 and 340 adjacent therecesses 322, 324 and 326, respectively. The purpose of the beveledsurfaces will be described below. The vertical wall 316 further includesa top surface 342 carrying three rearwardly projecting horizontalflanges 344, 346 and 348. As best seen in FIGS. 21 and 22, each sectionof the contact block 300 includes in the front face 332 thereof, aplurality of parallel, vertical grooves 350. Further, as seen in FIGS.20 and 24, the rear face 334 includes in each section of the wall 316 aplurality of parallel, vertically extending slots or grooves 352 inlongitudinal alignment with the grooves 350 in the front face 332 of thewall. As in the first embodiment of the contact block, each section ofthe contact block 300 includes a plurality of shaped contact wires 354.In the embodiment under consideration, the contact wires 354 are carriedby the horizontal flanges 344, 346 and 348. Thus, each contact wire 354includes a horizontal portion 356 part of which is embedded in theplastic forming the associated horizontal flange 344, 346 or 348. Eachcontact wire 354 further includes a rearwardly extending first terminalportion or solder tail 358 and a vertically extending portion 360disposed within one of the vertical grooves 350 formed in the front face332 of the wall. The vertically extending portion 360 of each contactwire 354 is held in place within the associated groove 350 byprojections 362 extending inwardly within the groove and engaging thewire portion 360. Each contact wire 354 has a curved, rear extremity364. From the rear extremity 364, the contact wire 354 is bent forwardlyto define a gently curved second terminal portion 366 adapted to beengaged by a corresponding contact wire on the RJ-type modular plugadapted to be electrically connected to the contact block. The forwardlyextending second terminal portion 366 of the contact wire 354 has aforward or free end 368 captured by one of the slots 352 formed in therear face of the vertical wall. It will thus be seen that the secondterminal portion 366 of each contact wire 354 is free to move up anddown in response to insertion and retraction of a modular plug, the sidewalls of the slot 352 constraining lateral movement of the free end 368of the contact wire. The second terminal portion 366 of the contact wireis so shaped and positioned, as best shown in FIG. 24, as to be firmlybiased into electrical contact with a corresponding terminal or contactwire on the modular plug upon insertion thereof. The horizontal andvertical portions 356 and 360 of contact wires 354 a that are not usedare clipped during production of the contact block.

FIGS. 23 and 24 show somewhat schematically the manner in which thecontact block 300 fits within a Type III card housing 370 in accordancewith the invention. The housing 370 has a rear portion 372 definingreceptacles, such as the receptacle 374, shaped and dimensioned tosnugly receive an RJ-type modular plug. In this regard, there isprovided a channel 376 formed in the rear portion 372 of the cardhousing along with appropriate lug means 378 adapted to be engaged, in amanner well known in the art, by the retention surfaces on the biasedclip of the modular plug. As seen in FIG. 24, the rearwardly extendingfirst terminal portion or solder tail 358 of each contact wire 354engages the upper surface 308 of the PCBA 310 and is soldered, forexample, by reflow soldering, to traces on the PCBA 310 along the rearmargin 311 thereof. The recesses 322, 324 and 326 and the beveledsurfaces 336, 338 and 340 defined by the wall 316 provide access to thesolder tails 358 for inspection and manually touching up the solderjoints, if necessary.

In assembling the contact block 300 and housing 370, the endprotuberances 330 on the contact block are seated within sockets (notshown) molded as part of the rear portion 372 of the housing. Similarly,the projections 331 on the contact block base 314 are received withinapertures 380 formed within the housing portion 372.

The rear portion 372 of the housing 370 includes a top wall 382 havingan inner surface 384 provided with recesses and grooves for receivingthe horizontal flanges 344, 346 and 348 and the horizontal portions ofthe contact wires 354. For example, as seen in FIG. 24, the portion ofthe inner surface 384 of the top wall 382 associated with the receptacle374 has a rectangular recess 386 for receiving the horizontal flange 346and grooves such as groove 388 for retaining the contact wire is 354,stabilizing its position and preventing damage to it upon insertion ofthe modular plug. It will be seen that the contact block 300 and thesolder tails 358 are so disposed as to be contained substantially withinthe confines of the recess 324 and connected to the traces on the rearmargin 311 of the PCBA 310 as close as practicable to the rear edgethereof. Thus, encroachment of the contact block 300 on the PCBA isminimized.

The second terminal portion 366 of each contact wire 354 is bent at anappropriate angle to provide a sufficiently long and therefore compliantforwardly extending terminal portion. By directing the solder tails orfirst terminal portions 358 of the contact wires 354 rearwardly, thereis no interference between any portion of the contact wires and the PCBAor any of the devices carried thereby.

It will thus be seen that the present invention successfully unitesstandard connectors and particularly RJ-type modular connectors, withthe standard Type III PCMCIA card architecture without violating theconstraints of either standard. Further, by providing an open bottom inthe receptacle, the retention clip, in the fully inserted position ofthe modular plus is permitted to project outwardly from the lower,horizontal outer surface of the card. Accordingly, the 10.5 mm height ofthe Type III card can incorporate a receptacle conforming to the FCC RJconnector standards. At the same time, by placing the lugs at the rearextremity of the receptacle, the depth of the receptacle has beenminimized, extending longitudinally, at most approximately 12 mm, sothat encroachment on adjacent PCBA space is minimized.

It will be evident that although it is preferable to orient thereceptacles so as to receive the associated plugs in a longitudinalinsertion direction, the orientation of the receptacles can be varied soas to receive the mating plugs in a direction that departs fromlongitudinal to some extent, so long as the upper and lower faces of theplug are maintained substantially parallel with the upper and lowerexterior surfaces of the receptacle-defining, rear portion of thedevice.

It further will be obvious that the receptacle body may be provided withvarious connector receptacle combinations besides the illustratedcombination comprising an RJ-11 modem receptacle, an RJ-45 Ethernetreceptacle, an RJ-11 pass-through and a slim D-sub connector receptacle.Alternatively, by way of example, the receptacle body could include anRJ-11 modem and pass-through receptacles; or a LAN RJ-45 receptacleonly; and so forth.

Further, the receptacle body can be adapted to connect the card to anyone or more of a plurality of data or information transfer systems, U.S.and/or foreign. Thus, by way of example and not limitation, FIG. 16shows a receptacle body 260 incorporating a mini-DIN connectorreceptacle 262; FIG. 17 depicts a receptacle body 264 housing a BNC/coaxconnector 266; FIG. 18 shows a receptacle body 268 supporting a D-subconnector 270; and FIG. 19 shows a receptacle body 272 including a USB(Universal Serial Bus) or IEEE-1394 connector 274. A particularreceptacle body may thus incorporate any one or a combination of thestandard connectors shown or other standard connectors of the many typesknown in the relevant industries, all within the Type III card formfactor and particularly the 10.5 mm height limitation.

It will also be seen that the combination of the plastic housing andbottom cover panel together define a frameless card enclosure therebymaximizing the usable PCBA surface area.

While the present invention has been described with reference toparticular illustrative embodiments, the invention is not intended to berestricted to those embodiments but only by the appended claims. It willbe appreciated that those skilled in the art can change or modify thedescribed embodiments, or substitute equivalents for the variouselements described and shown, without departing from the scope andspirit of the invention. For example, it will be evident that thecritical dimension is the cross section of the card, which cross sectionshould not exceed the PCMCIA standards. The card length could be madesomewhat longer than the PCMCIA card length of 85.0 mm although this isless desirable since additional length might project excessively fromthe host system.

What is claimed is:
 1. A device for use in a host system having a PCMCIAType III standard slot, the device being adapted to connect the hostsystem to an information transfer system, the device comprising: ahousing having longitudinal sides, a transverse front end and a rearportion, at least the rear portion of the housing having a thicknessconforming substantially to the PCMCIA Type III standard, the rearportion of the housing defining a forwardly extending receptacle sizedand configured to receive an RJ-type standard connector plug having aplurality of contacts; a substrate enclosed within the housing, thesubstrate carrying circuit elements; a connector at the front end of thehousing connected to circuit elements on the substrate and adapted tomate with a corresponding connector within the slot of the host system;and a contact block disposed within the rear portion of the housing, thecontact block having an overall height within the thickness confines ofthe rear portion of the housing, the contact block having a top portionand a plurality of side-by-side contact wire sections, each contact wiresection being adapted to carry a plurality of contact wires connected tocircuit elements on the substrate, the receptacle being in longitudinalalignment with one of the contact wire sections of the contact block, atleast the one contact wire section carrying a plurality of contactwires, each of the plurality of contact wires carried by the one contactwire section including a generally vertically oriented, U-shaped partextending rearwardly into the receptacle, the U-shaped part of each ofthe plurality of contact wires having an upper leg and a lower leg, theupper leg being generally horizontal and extending rearwardly from thetop portion of the contact block and having a rear extremity, the lowerleg extending forwardly from the rear extremity of the upper leg andhaving a free forward end, the lower leg being shaped and positioned forspring biased engagement with a corresponding contact on the connectorplug when the plug is inserted in the receptacle, wherein the device isadapted to be directly connectable to the information transfer systemutilizing the standard RJ-type connector plug.
 2. A device, as definedin claim 1, in which: each contact wire section of the contact blockincludes a generally horizontal flange extending rearwardly from the topportion of the contact block, the flange being adapted to support aportion of each of the plurality of contact wires adapted to be carriedby said contact wire section.
 3. A device, as defined in claim 1, inwhich: the contact block comprises three contact wire sections.
 4. Adevice, as defined in claim 1, in which: the receptacle is sized andconfigured to receive an RJ-45 connector plug.
 5. A device, as definedin claim 1, in which: the contact block comprises a one-piece, unitary,molded plastic structure.
 6. A device, as defined in claim 5, in which:the substrate includes a rear margin within the rear portion of thehousing; and the contact block is mounted on the rear margin of thesubstrate.
 7. A device, as defined in claim 1, in which: the rearportion of the housing defines a second forwardly extending receptaclein side-by-side relationship with the first mentioned receptacle, thesecond receptacle being sized and configured to receive an RJ-11connector plug and disposed in longitudinal alignment with a secondcontact wire section of the contact block, the second contact wiresection of the contact block carrying a plurality of contact wiresconnected to circuit elements on the substrate and substantiallyidentical in configuration to those carried by the one contact wiresection.
 8. A device, as defined in claim 7, in which: the rear portionof the housing defines a third forwardly extending receptacle inside-by-side relationship with the first and second receptacles, thethird receptacle being sized and configured to receive a second RJ-11connector plug and disposed in longitudinal alignment with the thirdcontact wire section of the contact block, the third contact wiresection of the contact block carrying a plurality of contact wiresconnected to circuit elements on the substrate and substantiallyidentical in configuration to those carried by the one contact wiresection.
 9. A device, as defined in claim 8, in which: the rear portionof the housing further defines a fourth forwardly extending receptaclein side-by-side relationship with the first, second and thirdreceptacles, the fourth receptacle being adapted to receive a cellularcommunications connector, the fourth receptacle including electricalcontacts connected to circuit elements on the substrate.